Led lamp for light source

ABSTRACT

Whereas incandescent light bulbs and other similar light sources known in the related art emit light in all directions, LED lamps can emit light in a single direction, and this is manifested in the problem of being unable to achieve light distribution characteristics satisfied by conventional headlamp designs. In accordance with an embodiment of the invention, an LED lamp for a light source of a headlamp can include an LED chip  2  in the vicinity of the focus of a projection means and a shielding member  7  covering a portion of the LED chip  2  in a formation allowing a light distribution characteristic suitable for a vehicle front-illumination light to be obtained when light from the LED chip  2  is magnified and projected in an illumination direction by a projection lens  10  or the like constituting the projection means. Accordingly, accurate light distribution characteristics can be obtained in a simple manner by projecting in the illumination direction using the projection lens  10.

This application is a Continuation application and claims priority under35 U.S.C. §120 of U.S. patent application Ser. No. 10/662,374 filed Sep.16, 2003 now U.S Pat. No. 7,019,334, and also claims the prioritybenefit under 35 U.S.C. §119 of Japanese Patent Application No.2003-169182 filed on Jun. 13, 2003. The above-referenced prioritydocuments are hereby incorporated in their entirety by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to LED lamps, and in particular, to theconfiguration of LED lamps used as light sources in vehicle lights.Furthermore, it relates to the configuration of an LED lamp suitable foruse as a light source in a vehicle lamp for illumination purposes thathas not previously been put to use as headlamps (or headlights),auxiliary headlamps (or fog lights), or the like.

2. Detailed Description of the Related Art

When LED lamps are used as a light source in flashlights and othersimilar lamps for the purpose of illumination in the related art, alarge LED chip is housed in a large package and light amount is obtainedby, for example, applying a current of between several ten and severalhundred milliamperes.

Simultaneously, as the package is made large in size, deterioration orbreakage of the LED chip as a result of overheating is prevented byeffectively conducting the heat emitted in the LED chip to the outsidewhen it is lit and discharging it to the atmosphere or the like. (Forexample, see Patent Document 1)

Patent Document 1

The Japanese Patent Laid-Open No. 2000-150968 (Paragraph 0011 throughParagraph 0034, FIG. 1)

Nevertheless, when a light fixture using an LED lamp as a light sourceis employed as a vehicle lamp fixture for a headlamp or the like, strictlight distribution characteristics are set forth in relevant standardsand other regulations with regard to prevent the drivers of oncomingvehicles from being dazzled by the light directed forwards. Furthermore,the configuration of lamps for the headlamp or the like is establishedin consideration of incandescent light bulbs and other similar itemsemitting light flux uniformly in almost all directions. Consequently,problems exist in that light distribution characteristics and the likecannot be satisfied by simply replacing the lamp with an LED lampradiating light in a single direction in a relatively large amount.

SUMMARY OF THE INVENTION

As a tangible means of resolving the problems known in the related art,an LED lamp for a light source of a headlamp can be characterized inthat an LED chip or a white LED light emission portion comprising an LEDlamp and fluorophor is disposed in the vicinity of the focus of aprojection means, and a shielding member covering a portion of the whiteLED light emission portion is provided in a formation allowing a lightdistribution characteristic suitable for a vehicle headlamp to beobtained when light from the white LED light emission portion ismagnified and projected in an illumination direction by the projectionmeans. Accordingly, the problems are resolved by enabling the regulatedlight distribution characteristics to be accurately and easily achievedeven when an LED lamp is used as a light source.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other characteristics, features and advantages of the presentinvention will become clear from following description with reference tothe accompanying drawing, wherein:

FIG. 1 is a perspective view showing an LED lamp for a light source of aheadlamp according to an embodiment of the present invention.

FIG. 2 is a cross-section view on A-A of FIG. 1.

FIG. 3 is an explanatory drawing showing a typical passing lightdistribution characteristic obtained by an embodiment of the presentinvention.

FIG. 4 is an explanatory drawing showing an embodiment of the LED lampfor the light source of the headlamp according to the present inventionwhen a projection lens is assembled thereto.

FIG. 5 is a cross-section view showing a typical configuration of ashielding member in the LED lamp for a light source of a headlampaccording to an embodiment of the present invention.

FIG. 6 is an explanatory drawing showing typical chromatic aberrationoccurring in a projection lens.

FIG. 7 is a cross-section view showing another typical configuration ofthe shielding member in the LED lamp for the light source of theheadlamp according to an embodiment of the present invention.

FIG. 8 is a cross-section view showing a further typical configurationof the shielding member in the LED lamp for the light source of theheadlamp according an embodiment of the present invention.

FIG. 9 is an explanatory drawing showing a typical configuration of theheadlamp light when a plurality of LED lamps for the light source of theheadlamp and projection lenses are combined.

FIG. 10 is an explanatory drawing showing a typical shaping method for alight distribution characteristic when a plurality of LED lamps for thelight source of the headlamp and projection lenses are combined.

FIG. 11 is an explanatory drawing showing a configuration when the LEDlamp for the light source of a headlamp according to an embodiment ofthe present invention is combined with a reflector.

REFERENCES

1: LED lamp for a light source of a headlamp

2: LED chip

3: Base unit

3 a: Base

3 b: Lead frame

3 c: Insulating layer

4: Metal wire

5: Fluorophor

6: Window glass member

7: Shielding member

7 a: Serrated section

8: White LED light emission portion

9: Silicone gel

10: Projection lens

11: Reflector

12: SiO₂ film

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Hereinafter, the present invention will be described by way of exemplaryembodiments thereof with reference to the accompanying drawings. Thepart indicated by reference 1 in FIG. 1 and FIG. 2 is an LED lamp for alight source of a headlamp according to an embodiment of the presentinvention (hereinafter referred to as an “LED lamp 1”), and in the LEDlamp 1, an LED chip 2 is mounted on a base unit 3.

The base unit 3 provides a base 3 a formed with a metal member of copperor some other metal excellent in heat conduction and a lead frame 3 balso formed with a metal member. The base 3 a and the lead frame 3 b areinsulated by an insulating layer 3 c formed with a resin member oranother similar insulating member. The LED chip 2 mounted on the base 3a is wired to the lead frame 3 b using a metal wire 4 or the equivalent,so the lighting can be carried out using power supplied from theexterior.

Considering the conditions to be satisfied for usage of the LED lamp 1as a light source for a headlamp, it can be seen that the regulatedcolor of the lamp is white or monochromatic yellow. Although white lightis used more often, no LED chip 2 that can directly emit white lightactually exists, and fluorophor 5 are used in combination in order toobtain white light.

As a first method of doing so, an LED chip 2 generating blue light and awavelength conversion member such as fluorophor 5 emitting yellow lightare combined, and white light is obtained by mixing the blue lightemitted directly from the LED chip 2 with the yellow light emitted fromthe fluorophor 5 excited by the light from the LED chip 2. As a secondmethod, furthermore, the LED chip 2 emitting ultra-violet light iscombined with fluorophor 5 emitting light of the three primaries red(R), green (G), and blue (B). In this case, the light emitted directlyfrom the LED chip 2 is not used as illumination light, and theillumination light from the LED lamp 1 comprises the light emitted fromthe fluorophor 5.

An embodiment of the present invention will hereinafter be described interms of a light source for a headlamp using a white LED light emissionportion 8 combining an LED chip 2 and fluorophor 5; nevertheless, insituations where it is required that the lamp color be yellow, forexample, it is possible for the light emitted directly from the LED chip2 to be used as the light for the light source. In such a situation,however, it is also possible for the embodiment of the present inventionto be implemented, and it is sufficient for the white LED light emissionportion 8 to be replaced by the LED chip 2 in this case.

Parts such as the LED chip 2, a metal wire 4, and fluorophor 5 aremechanically weak and do not have good resistance to humidity and othersimilar factors. Accordingly, these parts are covered by a lens-shapedmember formed from transparent resin or the like or by a window glassmember (the accompanying drawings show an example in which a windowglass member 6 is used), and through the action of this part and thebase 3 a, are sealed with respect to outside air. Thus, theabove-described parts are prevented from breaking as a result of contactwith the other parts, deteriorating as a result of humidity, and othersimilar factors. Furthermore, it is possible to fill inert gas, siliconegel, or the like (this explanation assumes usage of silicone gel 9) intothe space between the lens-shaped member or the window glass member andthe white LED light emission portion 8.

In addition, the LED lamp 2 according to an embodiment of the presentinvention provides a shielding member 7. Furthermore, this shieldingmember 7 covers a portion of the fluorophor 5, and for example, whenlight emitted from the fluorophor 5 is projected in the illuminationdirection by a projection lens or the like, allows a light distributionpattern for passing or any other desired light pattern to be obtained.

Accordingly, both the window glass member 6 and the shielding member 7are disposed more forward than the fluorophor in the illuminationdirection, and since the window glass member 6 is transparent and theshielding member 7 is opaque, either of these parts can be disposedforward of the other. Furthermore, the shielding member 7 can be freelyformed, for example, using the inner and outer surfaces of the windowglass member 6 with an opaque paint covering or vapor deposition ofmetallic member.

When a headlamp using the LED lamp 1 as a light source is used toprovide light for an infrared night-vision device, a member transmittingthe infrared light and shielding visible light-is used for the windowglass member 6, and in terms of the shielding member 7, it is sufficientto use a member shielding beam of light from infrared through visiblelight. Moreover, when the shielding member 7 is a vapor deposited filmwith the metallic member, deterioration as a result of oxidation andother similar factors are considered possible, and therefore, it isacceptable to provide protection by covering with a SiO₂ film asindicated by reference 12 in FIG. 2.

Reference HB from FIG. 3 indicates a typical passing light distributionpattern for left-hand drive situations. In this passing lightdistribution pattern RB, the half on the right of the vehicle centerlineconstitutes a light distribution pattern containing no upward directedlight in order to prevent the drivers of oncoming vehicles from beingdazzled. On the other hand, the half on the left of the vehiclecenterline contains a section called an “elbow” in which upward directedlight increases towards the left at an angle of 15.degree. in order toallow traffic signs and the like on the road side to be easilyidentified.

In an embodiment of the present invention, the shape of the portion ofthe fluorophor 5 not covered by the shielding member 7 is made similarto that of the above-mentioned passing light distribution pattern HB.Moreover, as shown in FIG. 4, the shape of the fluorophor 5 obtained inthis way is projected in the illumination direction P by a projectionlens 10 to obtain the passing light distribution pattern HB. In order toensure that highest intensity is in the front horizontal direction sothat good long-distance visibility can be assured, when the LED chip 2is covered by the shielding member 7, this is performed at the point ofhighest intensity or at a position in the vicinity thereof.

Horizontal and vertical inversion occurs after projection by theprojection lens 10, and therefore, the LED lamp 1 is mounted in theheadlamp in a 180.degree.-rotated condition, and when projection iscarried out by the projection lens 10 in this condition, an erect imageof the passing light distribution pattern HB can be obtained.Furthermore, by modifying the formation of the shielding member 7, lightdistribution patterns without an elbow, light distribution patterns fordriving, and other types of light distribution pattern can be freelyformed.

As a further description of the shielding member 7, it can be statedthat since the shielding member 7 shields the light from the LED chip 2,when half thereof is covered, the quantity of light is halved, and inthis way, loss occurs with respect to the quantity of light emitted fromthe LED chip 2. The results of studies by the inventors show that thetreatment of the surface at least opposing the LED chip 2 has a minoreffect on the shape of the light distribution characteristic formedafter projection.

That is to say, when the surface of the shielding member 7 (i.e., thesurface facing the projection lens 10) reflects light, this light isre-projected by the projection lens 10 and there is a high probabilitythat formation of the light distribution pattern will be adverselyaffected. Therefore, it may be helpful to provide non-reflectiontreatment of a color such as black. Nevertheless, a mirror finish isprovided to the rear surface, and even when the light emitted from theLED chip 2 is reflected, this light can substantially return only to theLED chip 2 side and has no substantial effect on the formation of theboundary between the fluorophor 5 and the shielding member 7, or inother words, on the formation of the shape of the light distributioncharacteristic.

The light reflected by the rear surface of the shielding member 7 isreturned to the inside of the fluorophor 5. Therefore, by providing, asshown in FIG. 5, a mirror finish on the rear surface of the shieldingmember 7 and, for example, a serrated section 7 a emitting light to bereflected in the direction of the non-covered portion of the fluorophor5, the brightness of light from the fluorophor 5 can be improved. Inother words, the light reaching the rear surface of the shielding member7 can be collected for use as illumination light, and it has beenconfirmed by trial manufacture and measurement by the inventors that thequantity of light increases by at least 15%.

Furthermore, results of simultaneous studies carried out by theinventors regarding the shielding member 7 showed that it is sometimeshelpful to perform projection with the focus of the projection lens 10aligned with the shielding member 7 in order to enable more preciseformation of the shape of the light distribution characteristic.Moreover, when brightness is required within the light distributioncharacteristic, it is possible to perform projection with the focus ofthe projection lens 10 aligned with the white LED light emission portion8 (or LED chip 2 when the lamp color is yellow). If the LED chip 2 andthe shielding member 7 are disposed in mutual proximity, the focus issubstantially aligned with both parts, and this condition is favorablein terms of both shape and brightness. Furthermore, a gap between bothof these parts of 2 mm or less may be helpful, and even better resultsmay be possible by reducing this gap to 1 mm or less.

In situations as explained above where the white LED light emissionportion 8 covered by the shielding member 7 is projected by theprojection lens 10, a single plano-convex lens is often used for theprojection lens 10. Therefore, as shown in FIG. 6, a difference occursin the position of, for example, the focus fb for blue light and thefocus fr for red light, resulting in what is known as chromaticaberration.

In such a case, if the shielding member 7 is disposed closer to any oneof such foci, coloration occurs in the terminator HL (see FIG. 3)corresponding to the portion of the passing light distribution patternHB in which the shape of the shielding member 7 is projected, and it istherefore impossible to satisfy the regulation requiring that the lightcolor be monochromatic. As a means of solving this problem, if thethickness t of the shielding member 7 is, for example, made to extendfrom the focus fb for the blue light to the focus fr for the red lightas shown in FIG. 7, and a plurality of colors are emitted on theprojected terminator HL, the color of the light emitted when this pluralcolors are mixed is close to white. Thus, it is possible to eliminate asense of specific colors being present.

Alternatively, as shown in FIG. 8, two or more thin shielding members 7are provided, and for example, the front and rear surfaces of the windowglass member 6 is used; furthermore, one of these thin shielding members7 is disposed at the position of the focus fb for the blue light, andthe other is disposed at the position of the focus fr for the red light.In accordance with this configuration, the blue light and the red lighthaving a substantially complimentary-color relationship are mixed on theprojected terminator HL of the passing light distribution pattern HB,and in the same way as explained above for the thick shielding member 7,it is possible to eliminate a sense of specific colors being present.

As a further description of the shielding member 7, it can be statedthat in addition to the chromatic aberration described above, aberrationfactors such as spherical aberration, astigmatism, coma, fieldcurvature, and distortion occur in the projection lens 10. As a resultof these aberration factors, shape distortion or focus displacementoccurs when the shape of the white LED light emission portion 8 isprojected.

Therefore, if the shielding member 7 is formed with the same curvatureas the curvature in the focus surface of the projection lens 10 in orderto countermeasure field curvature for example, it is possible to obtaina sharp terminator HL extending from the center to the right and left(provided that spherical aberration, astigmatism, and coma have noeffect). Furthermore, in response to distortion and other aberrationfactors that cause shapes to become distorted, it is sufficient tocorrect the shielding member 7 in such a way that the desired shape ofthe passing light distribution pattern is obtained after projection.

As explained above, all aberration factors can be resolved by methodssuch as thickening, curving, or transforming of the shielding member;however, no detailed explanation of these methods will be providedherein as such information is already publicly known in terms of a widerange of projector-type lamps using projector lenses 10.

FIG. 9 shows a schematic representation of another embodiment of aheadlamp lamp using an LED lamp 1 as a light source according to thepresent invention. FIG. 4 showed an illumination-lamp configurationcomprising a single LED lamp 1 and a single projection lens 10; however,while the white LED light emission portion 8 containing the shieldingmember 7 satisfies the regulations for the passing light distributionpattern HB in terms of shape, the illumination distribution providesinsufficient central illumination and other similar regulations may notbe satisfied.

Here, as the white LED light emission portion 8 with an extremely smallsurface area is directly projected, the projection lens 10 may also besmall. Accordingly, even if a plurality of combinations of an LED lamp 1and the projection lens 10 are provided, the dimensional requirementsfor a headlamp can be satisfied.

Accordingly, this embodiment sets the plurality of combinations of theLED lamp 1 and the projection lens 10 to, for example, three for asingle illumination lamp. In this case, the LED lamp 1 can be from thesame one used in the previous embodiment. However, as for the projectionlens 10, a No. 1 projection lens 10 a with a same magnification as theprojection lens 10 used in the FIG. 4, a No. 2 projection lens 10 b witha reduced magnification, and a No. 3 projection lens 10 c with a furtherreduced magnification are provided. All of these projection lensesperform projection in the same direction.

FIG. 10 shows the passing light distribution pattern HBs obtained from aheadlamp configured as explained above. Although this passing lightdistribution pattern HBs is same to the passing light distributionpattern HB (see FIG. 3) from the previous embodiment in terms of shape,it is formed into a prescribed shape by superimposing the lightdistribution pattern Ha from the No. 1 projection lens 10 a, the lightdistribution pattern Hb from the No. 2 projection lens 10 b, and thelight distribution pattern Hc from the No. 3 projection lens 10 a-c.

Accordingly, the light distribution pattern Hc from the No. 3 projectionlens 10 c having the lowest magnification is the brightest. Moreover, bydisposing this light distribution pattern Hc in the central area of thepassing light distribution pattern HBs, illumination for the frontdirection of a vehicle becomes brightest and long-distance visibility isimproved. Furthermore, regulations can be satisfied by adjusting themultiplicity of combinations of an LED lamp 1 and a projection lens 10and the magnification of the corresponding projection lenses 10 c.

In general, the quantity of light obtained from the LED lamp 1 is smallin comparison with that of the halogen bulbs and metal halide dischargedlamps used as light sources in the related art. Therefore, such a methodof increasing the number of combinations and the quantity of light isvery effective as a means of realizing the headlamp using the LED lamp 1as a light source.

In order to simplify the above explanation, the embodiment obtains thefinal passing light distribution pattern by superimposing a plurality oflight distribution patterns having a substantially identical shape anddifferent magnifications. However, the final passing light distributionpattern may be formed by joining a plurality of elements suitablydividing the shape of the final passing light distribution pattern. Inother words, it is sufficient to ultimately obtain the lightdistribution pattern that satisfies the regulations.

FIG. 11 shows an example of another projection method using the LED lamp1 according to an embodiment of the present invention. In this example,projection in the illumination direction P is carried out using, forexample, a reflector 11 having a paraboloid of revolution shape oranother similar shape having a focus instead of the projection lens 10constituting the previous projection means, thus realizing anillumination light with the prescribed light distribution pattern.

Accordingly, this projection method using the reflector 11 forming aprojection image using the reflected light disposes the LED chip 2, thefluorophor 5, the shielding member 7, and the like in opposition to thereflector, or in other words, the parts are disposed in proximitythereto facing approximately backward with respect to the illuminationdirection P.

If this reflector 11 is, for example, a multi-reflector combining aplurality of parabolic adjustable surfaces, a high degree of freedom isachieved when forming the passing light distribution pattern HB, andsince the chromatic aberration does not fundamentally occur in thereflector 11, the high quality passing light distribution pattern HB canbe easily obtained. Furthermore, as in the case of the projection lensexplained above, a plurality of combinations of the LED lamp 1 and thereflector 11 can be used in the realization of the headlamp.

As explained above, an LED lamp for a light source of a headlamp caninclude an LED chip in the vicinity of the focus of a projection meansand a shielding member covering a portion of the LED chip in a formationallowing a light distribution characteristic suitable for a headlamp ofa vehicle to be obtained when light from the LED chip is magnified andprojected in an illumination direction by the projection means.Accordingly, light distribution shapes with accurate characteristics canbe obtained in an extremely simple manner by projecting the shape of thelight emission portion of the solid construction constituted by the LEDlamp for a light source of a headlamp in the illumination directionusing a projection lens or a reflector, and thus, exceptional advantagesare achieved in the form of reliability improved by the solid statelight source, cost reduction by the simplified construction, and theability for compact designs.

While exemplary embodiments of the present invention have been shown anddescribed, it will be understood that the present invention is notlimited thereto, and that various changes and modification may be madeby those skilled in the art without departing from the scope of theinvention as set forth in the appended claims.

1. An LED lamp comprising: a base unit; an LED chip located in the baseunit and capable of emitting light in a light emitting direction; ashielding member located adjacent a portion of said LED chip, theshielding member forming a window that has a non-symmetrical shape whenviewed from the light emitting direction, the window located adjacentthe LED chip and in the light emitting direction of the LED chip suchthat a non-symmetrical light distribution characteristic is emitted fromthe lamp via the shielding member by the light emitted from the LEDchip, wherein the base unit includes an indent portion in which the LEDchip is located, and an at least partially transparent layer is locatedwithin the indent portion of the base unit and adjacent the LED chip. 2.The LED lamp of claim 1, wherein the LED lamp is a vehicle headlamp. 3.The LED lamp of claim 1, wherein the base unit includes an insulatinglayer that has an aperture located above the LED chip, and the shieldingmember is located within the insulating layer aperture.
 4. The LED lampof claim 1, wherein a surface of said shielding member facing towardsthe LED chip has a substantially mirrored finish.
 5. The LED lamp ofclaim 1, further comprising: a window member located above the shieldingmember in the light emitting direction.
 6. The LED lamp of claim 1,further comprising: a projection lens located adjacent the LED chip andconfigured to project the light emitted from the LED chip.
 7. The LEDlamp of claim 1, further comprising: a reflector located adjacent theLED chip and configured to reflect the light emitted from the LED chip.8. The LED lamp of claim 1, further comprising: an integral one piecelead extending into and from the base unit; and a bonding wire directlyconnected to the lead and to the LED chip.
 9. The LED lamp of claim 1,further comprising: a first light distribution characteristic formingstructure located adjacent the shielding member and configured to causethe light to have a first light distribution characteristic when emittedfrom the lamp; a second base unit; a second LED chip capable of emittinga second light and located in the second base unit; a second shieldingmember located adjacent a portion of said second LED chip, the secondshielding member forming a second window having a second shape such thatthe second light is emitted from the lamp via the second window of thesecond shielding member and having a shape defined by the second shape;and a second light distribution characteristic forming structure locatedadjacent the second shielding member and configured to cause the secondlight to have a second light distribution characteristic when emittedfrom the lamp, wherein the first light distribution characteristic isdifferent from the second light distribution characteristic.
 10. The LEDlamp of claim 9, wherein the LED lamp is a vehicle headlamp.
 11. The LEDlamp of claim 9, wherein the first light distribution characteristicforming structure is a projection lens.
 12. The LED lamp of claim 9,wherein the first light distribution characteristic forming structure isa reflector.
 13. The LED lamp of claim 9, wherein a surface of saidshielding member facing towards the LED chip has a substantiallymirrored finish.
 14. The LED lamp of claim 9, wherein the first lightdistribution characteristic is a first magnification, and the secondlight distribution characteristic is a second magnification, and thefirst magnification is different from the second magnification.
 15. TheLED lamp of claim 9, further comprising: a wavelength conversionmaterial located above the LED chip, wherein the base unit is integrallyconnected with the wavelength conversion material and shielding member,and the base unit forms an aperture and the shielding member andwavelength conversion material are located within the aperture of thebase unit.
 16. The LED lamp of claim 9, further comprising: an integralone piece lead extending into and from the base unit; and a bonding wiredirectly connected to the one piece lead and to the LED chip.
 17. An LEDlamp comprising: a base unit; an LED chip located in the base unit andcapable of emitting light in a light emitting direction; a shieldingmember located adjacent a portion of the LED chip, the shielding memberforming a window that has a non-symmetrical shape when viewed from thelight emitting direction, the window located adjacent the LED chip andin the light emitting direction of the LED chip such that anon-symmetrical light distribution characteristic is emitted from thelamp via the shielding member by the light emitted from the LED chip;and a wavelength conversion material located above the LED chip, whereinthe shielding member is located above the wavelength conversionmaterial, and no open space exists between the shielding member and theLED chip along the light emitting direction.
 18. An LED lamp comprising:a base unit; an LED chip located in the base unit; means for emitting anon-symmetrical light distribution located adjacent the LED chip andwithin the base unit; an integral one piece lead extending into and fromthe base unit; and a bonding wire directly connected to the lead and tothe LED chip.
 19. The LED lamp of claim 18, wherein the LED lamp is avehicle headlamp.
 20. The LED lamp of claim 18, wherein the base unitincludes an insulating layer that includes an aperture located above theLED chip, a substantially transparent material located above the LEDchip, and the means for emitting a non-symmetrical light distribution islocated within the insulating layer aperture and in contact with thesubstantially transparent material.